A racing car body structure

Abstract

The utility model belongs to new energy automobile structure design and manufacturing field discloses a race car body structure, including the upper frame of steel material, its welding becomes space truss structure, is used for forming the cockpit and the anti -roll protection area, is the main load bearing and protection unit, ensures when having enough safety stiffness in the crash or the roll; The lower chassis frame of aluminium alloy material, its welding becomes rectangular closed frame structure, is used for with suspension, battery, motor and transmission mechanism installation interface integration, is the load bearing platform and supports power system, suspension and electric control equipment, the bottom of space truss structure and the top of lower chassis frame are connected through bolt. The utility model upper frame uses steel material, lower chassis frame uses aluminium alloy material, both through bolt becomes the car body structure, the structure because steel-aluminium combination makes the car body have the quantitative performance, promotes the acceleration performance and energy consumption efficiency, steel-aluminium mixed structure stiffness is high, and the torsional performance is superior to the full aluminium and full steel frame of same size.

Description

Technical Field

[0001] This utility model belongs to the field of new energy vehicle structural design and manufacturing, specifically relating to a racing car body structure, which is suitable for new energy vehicle racing vehicles and teaching experimental vehicles. Background Technology

[0002] The design and manufacture of racing car bodies is a complex task that integrates materials science, aerodynamics and structural engineering. Its core objective is to ensure high strength, high rigidity and excellent performance while achieving extreme lightweighting.

[0003] Most existing new energy vehicle racing cars use a steel tube integral welded structure. However, this structure results in high overall strength but large mass of the racing car body, which is not conducive to lightweighting. In addition, racing cars also use a carbon fiber integral shell structure. However, although this shell structure is lightweight, it has high manufacturing cost, is difficult to maintain, and has uneven overall stiffness distribution, making it prone to local fatigue cracking. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model provides a racing car body structure. The upper frame is made of steel, and the lower chassis frame is made of aluminum alloy. The two are bolted together to form the car body structure. Due to the combination of steel and aluminum, the entire car body has high rigidity, which can effectively improve acceleration performance and energy efficiency during racing. In addition, the steel-aluminum hybrid structure has high rigidity and torsional resistance superior to all-aluminum and all-steel frames of the same size.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A racing car body structure, comprising, The steel upper frame is welded into a space truss structure to form the driver's cabin and roll protection area. As the main load-bearing and protection unit, it ensures that the vehicle has sufficient safety rigidity in the event of a collision or rollover. The lower chassis frame, made of aluminum alloy, is welded into a rectangular closed frame structure for integration with the mounting interfaces of the suspension, battery, motor, and transmission mechanism; it serves as a load-bearing platform and supports the power system, suspension, and electronic control equipment. The bottom of the space truss structure and the top of the lower chassis frame are connected by bolts.

[0006] Preferably, the space truss structure has a lower connecting part that extends vertically, and the top of the lower chassis frame has an upper connecting part. A nylon insulating gasket is provided between the upper connecting part and the lower connecting part. One end of the bolt is used to fix the space truss structure and the lower chassis frame through the lower connecting part, the nylon insulating gasket, and the upper connecting part.

[0007] Preferably, the nylon insulating gasket is installed on the upper and lower connecting parts by coating with an anti-corrosion insulating varnish layer, which is used to prevent electrochemical reactions.

[0008] Preferably, the bolt is an M8 high-strength bolt with a tightening torque of 25±2 N·m.

[0009] Preferably, the vehicle body structure further includes a carbon fiber composite material outer cover, which includes a front cover, side panels and a rear cover, which are respectively matched and fixedly covered on the upper frame to cover the front, side and rear of the upper frame to protect the interior components, enhance overall rigidity and achieve weight reduction.

[0010] Preferably, the upper frame is made of 4130 steel tubing, and the lower chassis frame is made of 6063 aluminum alloy rectangular tubing.

[0011] Preferably, a suspension mounting bracket is provided on the lower chassis frame for mounting the suspension; Motor mounting plate, used for mounting motors; Battery mounting holes are used to install batteries.

[0012] Preferably, the outer cover of the carbon fiber composite material has a thickness of 2-2.5 mm and a density of 1.5 g / cm³.

[0013] Compared with the prior art, the beneficial effects of this utility model are: 1. Because the upper frame of this utility model is made of steel and the lower chassis frame is made of aluminum alloy, and the two are installed by bolts to form a body structure, the steel-aluminum combination gives the entire body a weight-bearing performance, which can effectively improve acceleration performance and energy efficiency during racing. In addition, the steel-aluminum hybrid structure has high rigidity and torsional resistance better than all-aluminum and all-steel frames of the same size.

[0014] 2. Because this utility model also uses an outer cover to match and cover the front, side and rear of the upper frame; specifically, it is installed by riveting, and the outer cover is made of carbon fiber, so disassembly and replacement are simple and maintenance costs are low.

[0015] 3. Because the upper body of this utility model is made of welded steel pipes, the lower chassis frame is made of welded aluminum frames, and the outer covering is installed on the upper body by riveting, all using conventional processes, it is suitable for teaching and small-batch manufacturing.

[0016] 4. Because the structural design of this utility model adopts a modular design, it can be adapted to lightweight racing car platforms of different sizes and power systems. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the vehicle body structure in this utility model; Figure 2 This is a schematic diagram showing the upper frame and lower chassis frame of this utility model connected by bolts; Figure 3 This is a schematic diagram of the structure of this utility model with an outer cover.

[0018] In the diagram: Upper frame 1; Lower connecting part 11; Lower chassis frame 2; Bolt 3; Outer cover 4; Front cover 41; Side panel 42; Rear cover 43. Detailed Implementation

[0019] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the following embodiments are described in detail with reference to the accompanying drawings. It should be noted that the description of these embodiments is for the purpose of helping to understand this utility model, but does not constitute a limitation on this utility model.

[0020] like Figure 1 As shown, a racing car body structure includes, The upper frame 1 is made of 4130 steel pipe (with an outer diameter of Φ25mm and a wall thickness of 1.6mm); it is welded into a space truss structure to form the driver's cab and roll protection area, serving as the main load-bearing and protection unit to ensure that the vehicle has sufficient safety rigidity in the event of a collision or rollover. The lower chassis frame 2 is made of 6063 aluminum alloy rectangular tube (with a cross-sectional size of 30×30×2mm). It is welded into a rectangular closed frame structure and is used for the integration of mounting interfaces with the suspension, battery, motor and transmission mechanism; it serves as a load-bearing platform and supports the power system, suspension and electronic control equipment. The bottom of the space truss structure and the top of the lower chassis frame 2 are connected by bolts 3 (high-strength M8 bolts with a tightening torque of 25±2 N·m); The carbon fiber composite outer cover 4 (its material is mainly carbon fiber cloth and epoxy resin, its thickness is 2-2.5mm, and its density is 1.5g / cm³) includes a front cover 41, a side panel 42, and a rear cover 43. The three are respectively matched and fixedly covered on the upper frame 1 (specifically, the upper frame has reserved mounting positions for the front cover, side panel, and rear cover, so the front cover is matched and installed on the front cover mounting position, the side panel is matched and installed on the side panel mounting position, and the rear cover is matched and installed on the rear cover mounting position, and all are installed using existing technology, such as riveting). It is used to cover the front, side, and rear of the upper frame 1 to protect the internal components, enhance the overall rigidity, and achieve weight reduction.

[0021] The space truss structure has a lower connecting part 11, which extends vertically. The top of the lower chassis frame 2 has an upper connecting part 21. A nylon insulating gasket is provided between the upper connecting part 21 and the lower connecting part 11. One end of the bolt 3 is fixed to the space truss structure and the lower chassis frame 2 through the lower connecting part 11, the nylon insulating gasket and the upper connecting part 21.

[0022] Nylon insulating pads are installed on the upper connection portion 21 and the lower connection portion 11 by coating with an anti-corrosion insulating varnish layer, which is used to prevent electrochemical reactions.

[0023] In addition, the lower chassis frame 2 is equipped with a suspension mounting bracket for mounting the suspension; a motor bracket for mounting the motor; and battery mounting holes for mounting the battery.

[0024] The upper frame, lower chassis frame, the connection between the upper frame and the lower chassis frame, and the outer cover of this utility model are manufactured (installed) in the following ways: 1. Manufacturing of the upper frame: (1) Material preparation: Cut 4130 steel pipes according to the design dimensions, chamfer and clean the ends, and remove oil from the surface.

[0025] (2) Assembly and positioning: Arrange the steel pipes on the welding platform at the designed angle and fix them with special tooling fixtures to control the geometric error ≤2mm.

[0026] (3) Welding process: Argon arc welding (TIG) is used with a welding current of 80-90A and Ar2 protection is used. The welds are welded in the order of the stress path to avoid local thermal stress concentration.

[0027] (4) Post-weld treatment: After welding, allow the weld to cool naturally and use a rubber hammer to gently tap the weld to release stress and ensure that there is no obvious deformation in the welded area.

[0028] (5) Quality inspection: Visual inspection and penetration testing of the weld seam to confirm that there are no defects such as porosity and incomplete penetration.

[0029] 2. Manufacturing of the lower chassis frame: (1) Material preparation: 6063 aluminum alloy rectangular tubes are selected, and the cutting length is precisely processed according to the CAD unfolded dimensions.

[0030] (2) Positioning and spot welding: Use the lower chassis frame fixture for positioning, and spot weld each node to ensure the accuracy of shape and position.

[0031] (3) Welding and forming: Aluminum-specific argon arc welding is used to control welding deformation; the welding current is about 70A and the welding wire type is ER5356.

[0032] (4) Post-weld correction: After welding, use a flat platform to check the flatness, and the error is ≤1.5mm.

[0033] (5) Installation interface processing: Set the suspension mounting base, motor bracket and battery fixing hole on the frame, with hole diameter accuracy of ±0.2mm.

[0034] 3. Connection between the upper frame and the lower chassis frame: (1) Connection method: The upper frame and the lower chassis frame adopt a composite structure of welding and bolt connection. The upper weld is continuously welded, and the lower part is reinforced with bolts.

[0035] (2) Corrosion protection design: Nylon gaskets are attached to the steel-aluminum contact surface and coated with anti-corrosion insulating paint layer to avoid electrochemical reaction.

[0036] (3) Assembly inspection: After the overall welding is completed, geometric correction is performed, and the error of the center distance between the front and rear shafts is measured to be ≤3mm.

[0037] 4. Installation of outer cover (1) Procurement of carbon fiber boards: Select finished carbon fiber composite boards (thickness 2.0~2.5mm) with a density of about 1.5g / cm³.

[0038] (2) Cutting and processing: According to the three-dimensional shape design drawings, use a manual cutting machine or CNC sheet cutting machine to process the front cover, side cover and tail cover according to the dimensions.

[0039] (3) Drilling and trimming: Drill holes (Φ4mm) at the edge with a hole spacing of 80-100mm; grind and chamfer the edge to avoid stress concentration.

[0040] (4) Assembly and fixing: It is connected to the frame by aluminum brackets and (Φ4mm) aluminum rivets. The rivet spacing is uniform and the assembly gap is controlled within 2mm.

[0041] Tests have verified that this vehicle body structure has the following effects: (1) Static loading test: 2.5kN was applied to the anti-roll zone of the upper frame, and the maximum deformation was measured to be less than 2.0mm; (2) Torsional stiffness test: Load tests were conducted at both ends of the lower chassis frame, and the calculated torsional stiffness increased by approximately 12%; (3) Vehicle weight verification: The vehicle weighs approximately 165 kg, which is about 20% lighter than the traditional steel structure; (4) Durability test: During the driving test, no cracks or loosening were found in the welds and rivets, and the structure remained stable.

[0042] The above embodiments are preferred embodiments of this utility model and are not intended to limit the scope of protection of this utility model. Various modifications or variations that can be made by those skilled in the art without creative effort within the scope of the appended claims are still within the scope of protection of this patent.

Claims

1. A racing car body structure, characterized in that, include, The steel upper frame is welded into a space truss structure to form the driver's cabin and roll protection area. As the main load-bearing and protection unit, it ensures that the vehicle has sufficient safety rigidity in the event of a collision or rollover. The lower chassis frame, made of aluminum alloy, is welded into a rectangular closed frame structure for integration with the mounting interfaces of the suspension, battery, motor, and transmission mechanism; it serves as a load-bearing platform and supports the power system, suspension, and electronic control equipment. The bottom of the space truss structure and the top of the lower chassis frame are connected by bolts.

2. The racing car body structure according to claim 1, characterized in that: The space truss structure has a lower connecting part that extends vertically, and the top of the lower chassis frame has an upper connecting part. A nylon insulating gasket is provided between the upper connecting part and the lower connecting part. One end of the bolt is used to fix the space truss structure and the lower chassis frame through the lower connecting part, the nylon insulating gasket, and the upper connecting part.

3. The racing car body structure according to claim 2, characterized in that: The nylon insulating pad is installed on the upper and lower connecting parts by coating with an anti-corrosion insulating varnish layer, which is used to prevent electrochemical reactions.

4. A racing car body structure according to claim 1, characterized in that: The vehicle body structure also includes carbon fiber composite material outer coverings, which include a front cover, side panels and a rear cover. The three are respectively matched and fixed to cover the upper frame to cover the corresponding front, side and rear of the upper frame, so as to protect the interior components, enhance the overall rigidity and achieve weight reduction.

5. A racing car body structure according to claim 4, characterized in that: The outer cover of the carbon fiber composite material has a thickness of 2-2.5 mm and a density of 1.5 g / cm³.

6. A racing car body structure according to claim 1, characterized in that: The lower chassis frame is provided with a suspension mounting bracket for mounting the suspension. Motor mounting plate, used to mount the motor; Battery mounting holes are used to install batteries.

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